2004 GMC W5500 Forward

Here’s a breakdown of common issues and complaints associated with the 2004 GMC W5500 Forward, formatted for your website and focusing on accuracy and specific details:

The 2004 GMC W5500 Forward is a medium-duty cab-over truck popular for its maneuverability and cargo capacity in urban environments. It’s known for its utilitarian design and reliability, though like any vehicle of this age, it has its share of common problems. The primary engine option was the Isuzu 4HE1-TC 4.8L Turbo Diesel, producing around 175 horsepower and 347 lb-ft of torque. While owners appreciate its ease of maintenance and turning radius, common complaints revolve around parts availability (especially body panels), age-related wear and tear, and some specific engine and transmission issues.

Engine

Isuzu 4HE1-TC 4.8L Turbo Diesel

• Turbocharger Failure
  • Description/Symptoms: Loss of power, black smoke from the exhaust, whining noise from the turbocharger.
  • Solution: Replace the turbocharger. Inspect the oil supply line to the turbocharger for blockage.
  • Estimated Cost to Fix: $1500 - $2500+
  • Recalls: None Found
• Fuel Injector Issues
  • Description/Symptoms: Rough idling, misfires, poor fuel economy, black smoke.
  • Solution: Diagnose which injector(s) are failing and replace them. May also require cleaning the fuel system.
  • Estimated Cost to Fix: $400 - $1200+ (depending on the number of injectors)
  • Recalls: None Found
• EGR Valve Problems
  • Description/Symptoms: Rough idling, stalling, check engine light (often with EGR-related codes).
  • Solution: Clean or replace the EGR valve. Check EGR cooler for leaks or blockages.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Cooling System Issues
  • Description/Symptoms: Overheating, coolant leaks, frequent coolant refills needed.
  • Solution: Pressure test the cooling system to find leaks. Replace radiator, hoses, water pump, or thermostat as needed.
  • Estimated Cost to Fix: $300 - $1000+ (depending on parts needed)
  • Recalls: None Found

Transmission

No engine option specified.

• Aisin A465 4-Speed Automatic Transmission - Slipping/Harsh Shifting
  • Description/Symptoms: Delayed engagement, slipping between gears, harsh shifts, transmission overheating.
  • Solution: Diagnose the cause – could be low fluid, worn clutches, or valve body issues. Transmission fluid service, valve body rebuild, or complete transmission replacement.
  • Estimated Cost to Fix: $200 (fluid service) - $4000+ (transmission replacement)
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Vehicle leaning to one side, rough ride, reduced load capacity.
  • Solution: Replace the leaf springs. Consider upgrading to heavier-duty springs if carrying heavy loads frequently.
  • Estimated Cost to Fix: $500 - $1500+ (depending on the number of springs and shop labor)
  • Recalls: None Found
• Worn Shocks/Struts
  • Description/Symptoms: Bouncy ride, excessive body roll in turns, poor handling.
  • Solution: Replace the shocks/struts.
  • Estimated Cost to Fix: $200 - $600+ (depending on the brand and shop labor)
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, lights flickering, sensors malfunctioning.
  • Solution: Inspect wiring harnesses for damage, corrosion, or loose connections. Repair or replace damaged sections of the harness.
  • Estimated Cost to Fix: $100 - $1000+ (depending on the severity and location of the damage, labor is a large component)
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery light on, dimming lights, battery not charging.
  • Solution: Replace the alternator. Check the battery condition and replace if needed.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust forming on the chassis, body panels, and around wheel wells. Especially prevalent in areas with road salt.
  • Solution: Remove rust, repair any damage, and repaint. Address the underlying cause of the rust.
  • Estimated Cost to Fix: $200 - $2000+ (depending on severity and area affected)
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: Blower motor not working, weak airflow.
  • Solution: Replace the blower motor. Check the blower motor resistor.
  • Estimated Cost to Fix: $100 - $300+
  • Recalls: None Found

Summary

The 2004 GMC W5500 Forward is a generally reliable truck, but owners should be aware of potential issues related to its age and typical usage. The most significant concerns revolve around the Isuzu diesel engine and the Aisin automatic transmission. Turbocharger failure, fuel injector issues, and EGR valve problems are not uncommon and can be expensive to repair. Rust is also a concern, especially in northern climates. Suspension and electrical problems can arise. The severity of these issues ranges from minor inconveniences to major repairs costing thousands of dollars. A thorough inspection is essential before purchasing a used 2004 GMC W5500 Forward.